Prefabricated rooms, bathrooms and bathroom floors

ABSTRACT

A prefabricated structure that may be fabricated prior to being installed withing a site and a method of installing the prefabricated structure within the site are described. The prefabricated structure may include a floor, vertical support bars, horizontal support bars, and angular support bars.

CROSS-REFERENCE TO RELATED APPLICATION DATA

This non-provisional application claims priority to U.S. provisional application No. 61/893,877 filed on Oct. 21, 2013.

FIELD

This disclosure relates generally to prefabricated construction structures and the construction thereof and, more particularly, to prefabricated rooms and bathrooms and the construction thereof.

BACKGROUND

Typical floors of rooms within buildings are oriented at various angles and therefore drain at different rates. Thus, there is a need for prefabricated structures having uniform drainage profiles that can be implemented into conventional finished and unfinished buildings.

SUMMARY

A prefabricated structure for placement in an outer structure having a floor, vertical support bars attached to the floor, horizontal support bars attached to the vertical support bars, angular support bars attached to the vertical support bars, and connection members for connecting the structure to the outer structure is described. The outer structure may be a greater structure of the building or job site.

Additional features and advantages of the present disclosure are described below. This disclosure may be readily utilized as a basis for modifying or designing other structures, systems, and processes for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent implementations do not depart from the teachings of the disclosure as set forth in the appended claims. The novel features, which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages, will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The particular features and advantages of the present disclosure will be apparent from the detailed description set forth below in conjunction with the drawings in which like reference characters identify corresponding aspects throughout.

FIG. 1 is a perspective view of a prefabricated structure according to embodiments of the present disclosure.

FIG. 2 is a perspective view of a floor of a prefabricated structure according to embodiments of the present disclosure.

FIG. 3 is a cross-sectional view of a floor of a prefabricated structure according to embodiments of the present disclosure.

FIG. 4 is a cross-sectional view of a floor of a prefabricated structure according to embodiments of the present disclosure.

FIG. 5 is a process flow diagram of installing a prefabricated structure according to embodiments of the present disclosure.

DETAILED DESCRIPTION

The detailed description set forth herein makes reference to the accompanying drawings, which show various aspects of the present disclosure by way of illustration. While these various aspects are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments and implementations may be realized and that logical and mechanical changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not limited to the order presented. Moreover, references to a singular embodiment may include plural embodiments, and references to more than one component may include a singular embodiment, for example.

The present disclosure relates to a prefabricated structure capable of being constructed offsite (i.e., at an area other than the final installation site of the prefabricated structure). The prefabricated structure may be installed in a variety of different structures, such as residential and commercial buildings of various shapes and sizes. The prefabricated structure allows for uniform drainage, because angles of the prefabricated structure can be preset prior to installation.

According to an aspect of the present disclosure, a prefabricated structure 100 is described with reference to FIGS. 1 and 2. The prefabricated structure 100 may include a floor 102, vertical support bars 104, horizontal support bars 106, and angular support bars 108. In various embodiments, the prefabricated structure 100 may also include aligning elements (not illustrated) that align the prefabricated structure 100 within a preexisting building. The aligning elements may be attached to the floor 102, vertical support bars 104, horizontal support bars 106, and/or angular support bars 108.

The floor 102 may have any shape, such as rectangular, circular, ovular, or any other conventional or non-conventional shape. The floor 102 may also have any number of sides. Additionally, the floor's 102 sides may have uniform lengths or may have varying lengths. According to an illustrative embodiment, the floor 102 may have ten sides of varying lengths. The floor 102 may be made of any material capable of providing adequate structural support to the prefabricated structure 100.

The floor 102 may be comprised of a single polymer material. It should also be appreciated that the floor 102 may be comprised of multiple materials without deviating from the scope of the present disclosure. In an embodiment, the floor 102 may be comprised of at least a high strength polymer concrete having a sand base.

The floor 102 may further have any size or thickness capable of providing adequate support to the prefabricated structure 100 and capable of fitting within residential and non-residential buildings. The thickness of the floor 102 may be uniform throughout the floor 102. However, it should also be appreciated that the thickness of the floor 102 may be non-uniform without deviating from the scope of the present disclosure. This may allow for the floor's 102 drainage profile to be determined prior to fabrication and set during fabrication, thereby preventing the need to set the drainage angle of the prefabricated structure 100 at the installation site. According to an embodiment, the prefabricated structure 100 may be a bathroom having a floor 102 with a non-uniform thickness. For example, the floor 102 may have a thickness of about 1.5 inches near or at edges of the floor 102 and a thickness of about 1 inch near or at drains located within the floor 102.

The floor 102 may additionally be constructed to withstand about 9,350 psi of pressure at 7 days and about 10,190 psi of pressure at 30 days. The floor 102 may also be constructed to allow about 2 Coulombs to about 8 Coulombs of charge to pass through the floor 102.

According to an illustrative embodiment, edges of the floor 102 may be surrounded by a substantially non-malleable material, such as metals including iron or steel for example, to assist in supporting the floor 102 from load bearings of vertical, horizontal, and angular support bars 104, 106, and 108. The floor 102 may also include a fiberglass cloth that reinforces the structural integrity of the floor 102. The fiberglass cloth may be located upon a surface of the floor 102. However, it should also be appreciated that the fiberglass cloth may be located within the floor 102 without deviating from the scope of the present disclosure.

The vertical support bars 104 may be permanently or removably attached to the floor 102 at or proximate edges of the floor 102. Such attachment may occur through a variety of means, such as welding, epoxy, and/or mechanical fasteners, for example, and may also include the use of brackets permanently or removably attached to one or both of the vertical support bars 104 and the floor 102. Mechanical fasteners may include, for example, bolts, screws, and pins. In an embodiment, the vertical support bars 104 attach to the floor 102 at regular intervals along the floor 102. However, the vertical support bars 104 may be attached to the floor 102 at irregular intervals along the floor 102 without departing from the scope of the present disclosure. The vertical support bars 104 may be comprised of any material and have any length and/or shape capable of providing adequate structural integrity to the prefabricated structure 100.

The horizontal support bars 106 may be permanently or removably attached to the floor 102 and/or the vertical support bars 104. Such attachment may occur through a variety of means, such as welding, epoxy, and/or mechanical fasteners, for example, and may also include the use of brackets permanently or removably attached to the floor 102, the vertical support bars 104, and/or the horizontal support bars 106. Mechanical fasteners may include, for example, bolts, screws, and pins. In an embodiment, the horizontal support bars 104 may attach to the vertical support bars 104 at regular intervals along the vertical support bars 104. However, the horizontal support bars 106 may also attach to the vertical support bars 104 at irregular intervals along the vertical support bars 104 without departing from the scope of the present disclosure. The horizontal support bars 106 may be comprised of any material and may have any length and/or shape capable of providing adequate structural integrity to the prefabricated structure 100. According to an embodiment, the horizontal support bars 106 may be comprised of the same material as the vertical support bars 104. In another embodiment, the horizontal support bars 106 may have lengths equal to or substantially equal to lengths of the floor's 102 edges. Additionally, the vertical and horizontal support bars 104 and 106 may be configured to form door and/or window holes within sides of the prefabricated structure 100.

The angular support bars 108 may be permanently or removably attached to the floor 102, vertical support bars 104, and/or horizontal support bars 106. Such attachment may occur through a variety of means, such as welding, epoxy, and/or mechanical fasteners, for example. Attachment may also include the use of brackets permanently or removably attached to the floor 102, vertical support bars 104, horizontal support bars 104, and/or angular support bars 108. Mechanical fasteners may include, for example, bolts, screws, and pins. The angular support bars 108 may be comprised of any material and may have any length and/or shape capable of providing adequate structural integrity to the prefabricated structure 100. According to an embodiment, the angular support bars 106 may be comprised of the same material as the vertical and/or horizontal support bars 104 and 106.

According to multiple embodiments, the floor 102 is further described with reference to FIGS. 3 and 4. The floor 102 may include a base layer 302, at least one rebar 304, at least one galvanized wire 306, a fiberglass cloth 308, and at least one edge protector 310.

The base layer 302 may be comprised of a single polymer material. It should be appreciated that the base layer 302 may also be comprised of multiple materials without deviating from the scope of the present disclosure. In an embodiment, the base layer 302 may be comprised of at least a high strength polymer concrete having a sand base. The base layer 302 may also have any size or thickness capable of providing adequate structural support to the prefabricated structure 100. Further, the base layer 302 may have a uniform thickness or may have a non-uniform thickness.

At least one rebar 304 may be located within the base layer 302. However, it should be appreciated that the at least one rebar 304 may be located along a surface of the base layer 302 without departing from the scope of the present disclosure. According to multiple embodiments, multiple rebar 304 may be located parallel to each other and may have lengths that enable each end of the rebars 304 to communicate with edges of the base layer 302. However, it should also be appreciated that multiple rebar 304 may be located at non-parallel orientations with respect to each other and may have lengths that prevent the rebars 304 from communicating with edges of the base layer 302. In an illustrative embodiment, the rebar 304 may have a thickness equal to ⅜ of an inch. However, the rebar 304 may have thicknesses not equal to ⅜ of an inch without departing from the scope of the present disclosure. In another embodiment, each rebar 304 may have the same thickness. However, in other embodiments, each rebar 304 may have a different thickness.

At least one galvanized wire 306 may be located within the base layer 302. However, it should be appreciated that the at least one galvanized wire 306 may be located along a surface of the base layer 302 without deviating from the scope of the present disclosure. According to various embodiments, multiple galvanized wires 306 may be located parallel to each other and may have lengths that enable ends of each galvanized wire 306 to communicate with edges of the base layer 302. However, it should be appreciated that the multiple galvanized wires 306 may be located at non-parallel orientations with respect to each other and may have lengths that prevent the multiple galvanized wires 306 from communicating with edges of the base layer 302. The galvanized wire 306 may have any thickness. In an illustrative embodiment, multiple galvanized wires 306 may all have the same thickness. However, in other embodiments, the multiple galvanized wires 306 may have different thicknesses.

The fiberglass cloth 308 may be located within or upon a surface of the base layer 302 and may be parallel to planes of the rebar 304 and/or the galvanized wire 306. The fiberglass cloth 308 may also be located parallel to at least one surface of the base layer 302. However, it should be appreciated that the fiberglass cloth 308 may have a non-parallel orientation with respect to the planes of the rebar 304 and/or the galvanized wire 306, as well as a non-parallel orientation with respect to the at least one surface of the base layer 302. In an embodiment, the fiberglass cloth 308 may have the same or substantially same shape as the base layer 302. In another embodiment, the fiberglass cloth 308 may have a size that allows the fiberglass cloth 308 to communicate with edges of the base layer 302. In a further embodiment, the fiberglass cloth 308 may have a size that prevents the fiberglass cloth 308 from communicating with edges of the base layer 302.

The edge protectors 310 may be located along all of the edges of the base layer 302 or may only be located along some of the edges of the base layer 302. In an embodiment, the edge protectors 310 may be comprised of a substantially non-malleable material, such as iron or steel, for example. However, it should be appreciated that the edge protectors 310 may be comprised of any material capable of providing adequate structural support to edges of the base layer 302. In an illustrative embodiment, the edge protectors 310 may have a first wall having a length of about 1.5 inches and a second wall having a length of about 2 inches. In another embodiment, the first and second walls may have a perpendicular orientation. However, it should be appreciated that the first and second walls of the edge protectors 310 may have different lengths and may be configured at other respective angles to one another without departing from the scope of the present disclosure.

According to yet another embodiment, the edge protectors 310 may be permanently or removably attached to the rebars 304. This attachment may occur through a variety of means, such as welding, epoxy, and/or mechanical fasteners. Mechanical fasteners may include, for example, bolts, screws, and pins.

In a further embodiment, the floor 102 may include a waterproof membrane (not illustrated) that inhibits stain causing mold and mildew growth. The waterproof membrane may be located along a top surface of the base layer 302. In an embodiment, the waterproof membrane may be located along a top surface of the fiberglass cloth 308. The waterproof membrane may have any thickness sufficient to provide a water proofing surface. In an embodiment, the waterproof membrane may have a thickness of about 0.02 inches.

According to another aspect of the present disclosure, a method 500 of installing a prefabricated structure is described with reference to FIG. 5. At block 502 a prefabricated structure is placed at a location within a site. The prefabricated structure may have the characteristics and configurations described herein with reference to the prefabricated structure 100. The site may be, for example, a completed or uncompleted construction site. The site may also be, for example, a completed or uncompleted residential or commercial building. At block 504 the prefabricated structure may be maneuvered using aligning elements incorporated into the prefabricated structure. The aligning elements may be incorporated into the prefabricated structure during construction of the prefabricated structure, after construction of the prefabricated structure but before placement of the prefabricated structure in the site, or the aligning elements may be incorporated into the prefabricated structure after it is placed at a desired location within the site. At block 506 the prefabricated structure is interconnected with the site. This may include running wires through the prefabricated structure. This may also include connecting piping to the prefabricated site, such as plumbing and ventilation piping, for example.

In other embodiments, at least partially prefabricated panels, the tub or shower pan, the finishing face trim, and/or other components may be shipped separately to the construction site for on-site assembly.

In view of the foregoing, it would be desirable to provide a prefabricated room or bathroom structure and methods of its manufacture and installation, for example, for use in reducing the time required to install bathrooms in comparison to traditional on-site construction.

The present disclosure is in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims. 

What is claimed is:
 1. A prefabricated structure for placement in an outer structure, comprising: (a) a floor, (b) vertical support bars attached to the floor, (c) horizontal support bars attached to the vertical support bars, (d) angular support bars attached to the vertical support bars, and (e) connection members for connecting the structure to the outer structure.
 2. The structure as claimed in claim 1, wherein the floor has a uniform thickness.
 3. The structure as claimed in claim 1, further comprising utility conduits for cables, wires, and drainage.
 4. The structure as claimed in claim 1, wherein the connection members connect the structure to a top portion of the outer structure.
 5. The structure as claimed in claim 1, wherein the structure is substantially entirely fabricated off site for delivery to a construction site.
 6. A prefabricated structure comprising: (a) a floor having a first thickness proximate edges of the floor and a second thickness distant edges of the floor, the first thickness being greater than the second thickness; (b) vertical support bars attached to the floor, (c) horizontal support bars attached to the vertical support bars, (d) angular support bars attached to the vertical support bars, and (e) connection members for connecting the structure to an outer structure.
 7. The structure as claimed in claim 6, further comprising utility conduits for cables, wires, and drainage.
 8. The structure as claimed in claim 6, wherein the connection members connect the structure to a top portion of the outer structure.
 9. The structure as claimed in claim 6, herein the structure is substantially entirely fabricated off site for delivery to a construction site.
 10. A method of installing a prefabricated structure comprising: placing/raising a prefabricated structure at a location within a site, the prefabricated structure having a floor, vertical support bars attached to the floor, and horizontal support bars attached to the vertical support bars; maneuvering the prefabricated structure using aligning elements, the aligning elements being incorporated into the prefabricated structure; and locking the structure to an outer structure.
 11. The method of claim 10, wherein the structure has pre-assembled water, power, and data conduits.
 12. The method as claimed in claim 10, wherein the structure is substantially entirely fabricated off site for delivery to the site. 